Payload fairing with improved acoustic suppression

Abstract

A fairing for protecting a payload from excessive acoustic energy is disclosed. The fairing can be used with a launch vehicle for launching payloads such as satellites or the like. The invention provides structure to surround a payload and absorbs acoustic energy so that the noise is suppressed to acceptable levels and the payload is not damaged. The fairing comprises a two dimensional honeycomb core having composite face sheets and load skins bonded to each side of the core. A water barrier is connected to the inner side of the fairing to prevent moisture from entering the payload area. The fairing may include an energy absorbing blanket connected to the inner side of the fairing to further suppress the energy generated by a launch vehicle.

What is claimed is:  
     
       1. A payload fairing wall for use with a fairing for a launch vehicle, the fairing wall comprising: 
       (a) an inner skin having an inside surface and an outside surface;  
       (b) a modified honeycomb layer, the modified honeycomb layer being comprised of a plurality of half-hexagons, the modified honeycomb layer having an inside surface and an outside surface, the inside surface of the modified honeycomb layer connected to the outside surface of the inner skin; and  
       (c) an outer skin having an inside surface and an outside surface, the inside surface of the outer skin connected the outside surface of the modified honeycomb layer.  
     
     
       2. The fairing wall of claim  1  further comprising a water barrier connected to the inner skin. 
     
     
       3. The fairing wall of claim  1  further comprising a thermal protection layer connected to the outside surface of the outer skin. 
     
     
       4. The fairing wall of claim  3  further comprising an environmental seal connected to the thermal protection layer. 
     
     
       5. The fairing wall of claim  4  wherein the environmental seal is conductive paint. 
     
     
       6. The fairing wall of claim  1  wherein the modified honeycomb layer is aluminum. 
     
     
       7. The fairing wall of claim  1  further comprising an acoustic blanket connected to the inside surface of the inner skin. 
     
     
       8. The fairing wall of claim  1  wherein the inner skin comprises a first face sheet of carbon fiber/epoxy fabric. 
     
     
       9. The fairing wall of claim  8  wherein the inner skin further comprises a first load skin layer of carbon fiber/epoxy tape. 
     
     
       10. The fairing wall of claim  1  wherein the outer skin comprises a second face sheet of carbon fiber/epoxy fabric. 
     
     
       11. The fairing wall of claim  10  wherein the outer skin further comprises a second load skin layer of carbon fiber/epoxy tape. 
     
     
       12. A shroud for use with a launch vehicle, the shroud comprising: 
       (a) a base portion having a wall, comprising:  
       (i) a first face sheet having an inside surface and an outside surface;  
       (ii) a first load skin layer having an inside surface and an outside surface, the outside surface of the first load skin connected to the inside surface of the first face sheet;  
       (iii) a modified honeycomb layer having an inside surface and an outside surface, the outside surface of the modified honeycomb layer connected to the inside furface of the first loas skin layer;  
       (iv) a second load skin layer having an inside surface and an outside surface, the outside surface of the second load skin connected the inside of the modified honeycomb layer;  
       (v) a water barrier layer having an inside surface and an outside surface, the outside surface of the water barrier layer connected to the inside surface of the second load skin; and  
       (vi) a second face sheet having an inside surface and an outside surface, the outside surface of the second face sheet connected to the inside surface of the water barrier layer;  
       (b) a nose cone portion connected to the base portion, the nose cone portion having a wall comprising:  
       (i) a first face sheet having an inside surface and an outside surface;  
       (ii) a first load skin layer having an inside surface and an outside surface, the outside surface of the first load skin connected to the inside surface of the first face sheet;  
       (iii) a honeycomb layer having an inside surface and an outside surface, the outside surface of the honeycomb layer connected to the inside surface of the first load skin layer;  
       (iv) a second load skin layer having an inside surface and an outside surface, the outside surface of the second load skin connected the inside surface of the honeycomb layer;  
       (v) a water barrier layer having an inside surface and an outside surface, the outside surface of the water barrier layer connected to the inside surface of the water barrier layer; and  
       (vi) a second face sheet having an inside surface and an outside surface, the outside surface of the second face sheet connected to the inside surface of the water barrier layer; and  
       (c) a nose cap portion connected to the nose cone portion, the nose cap portion having a wall comprising:  
       (i) a first face sheet having an inside surface and an outside surface;  
       (ii) a first load skin layer having an inside surface and an outside surface, the outside surface of the first load skin connected to the inside surface of the first face sheet;  
       (iii) a honeycomb layer having an inside surface and an outside surface, the outside surface of the honeycomb layer connected to the inside surface of the first load skin layer;  
       (iv) a second load skin layer having an inside surface and an outside surface, the outside surface of the second load skin connected the inside surface of the honeycomb layer;  
       (v) a water barrier layer having an inside surface and an outside surface, the outside surface of the water barrier layer connected to the inside surface of the second load skin; and  
       (vi) a second face sheet having an inside surface and an outside surface, the outside surface of the second face sheet connected to the inside surface of the water barrier layer.  
     
     
       13. A payload fairing wall for use with a fairing for a launch vehicle, the fairing wall comprising: 
       (a) a first face sheet having an inside surface and an outside surface;  
       (b) a first load skin layer having an inside surface and an outside surface, the outside surface of the first load skin connected to the inside surface of the first face sheet;  
       (c) a modified honeycomb layer, the modified honeycomb layer being comprised of a plurality of half-hexagons, the modified honeycomb layer having an inside surface and an outside surface, the outside surface of the modified honeycomb layer connected to the inside surface of the first load skin layer;  
       (d) a second load skin layer having an inside surface and an outside surface, the outside surface of the second load skin connected the inside surface of the modified honeycomb layer;  
       (e) a water barrier layer having an inside surface and an outside surface, the outside surface of the water barrier layer connected to the inside surface of the second load skin; and  
       (f) a second face sheet having an inside surface and an outside surface, the outside surface of the second face sheet connected to the inside surface of the water barrier layer.  
     
     
       14. The fairing wall of claim  13  further comprising a thermal protection layer connected to the outside surface of the first face sheet. 
     
     
       15. The fairing wall of claim  14  further comprising an environmental seal connected to the thermal protection layer. 
     
     
       16. The fairing wall of claim  15  wherein the environmental seal is conductive paint. 
     
     
       17. The fairing wall of claim  13  wherein the modified honeycomb layer is aluminum. 
     
     
       18. The fairing wall of claim  13  further comprising an acoustic blanket connected to the inside surface of the second face sheet. 
     
     
       19. The fairing wall of claim  13  wherein the first face sheet is carbon fiber fabric impregnated with epoxy resin. 
     
     
       20. The fairing wall of claim  13  wherein the first load skin layer is carbon fiber tape impregnated with epoxy resin. 
     
     
       21. The fairing wall of claim  13  wherein the modified honeycomb layer is TRUSSGRID material. 
     
     
       22. The fairing wall of claim  13  wherein the second face sheet is carbon fiber fabric impregnated with epoxy resin. 
     
     
       23. The fairing wall of claim  13  wherein the second load skin layer is carbon fiber tape impregnated with epoxy resin. 
     
     
       24. A payload fairing for use with a launch vehicle, comprising: 
       (a) a base portion having a wall comprising:  
       (i) a first face sheet having an inside surface and an outside surface and made of carbon fiber/epoxy fabric;  
       (ii) a first load skin layer having an inside surface and an outside surface and made of carbon fiber/epoxy tape, the outside surface of the first load skin connected to the inside surface of the first face sheet;  
       (iii) a modified honeycomb layer, the modified honeycomb layer being comprised of a plurality of half-hexagons, the modified honeycomb layer having an inside surface and an outside surface, the outside surface of the modified honeycomb layer connected to the inside surface of the first load skin layer;  
       (iv) a second load skin layer having an inside surface and an outside surface and made of carbon fiber/epoxy tape, the outside surface of the second load skin connected the inside surface of the modified honeycomb layer;  
       (v) a water barrier layer having an inside surface and an outside surface, the outside surface of the water barrier layer connected to the inside surface of the second load skin; and  
       (vi) a second face sheet having an inside surface and an outside surface and made of carbon fiber/epoxy fabric, the outside surface of the second face sheet connected to the inside surface of the water barrier layer;  
       (b) a nose cone portion connected to the base portion; and  
       (c) a nose cap portion connected to the nose cone portion.  
     
     
       25. The base portion of claim  24  further comprising a thermal protection layer connected to the outside surface of the first face sheet. 
     
     
       26. The base portion wall of claim  25  further comprising an environmental seal connected to the thermal protection layer. 
     
     
       27. The base portion wall of claim  26  wherein the environmental seal is conductive paint. 
     
     
       28. The base portion wall of claim  24  wherein the modified honeycomb layer is aluminum. 
     
     
       29. The base portion wall of claim  24  further comprising an acoustic blanket connected to the inside surface of the second face sheet. 
     
     
       30. The base portion wall of claim  24  wherein the water barrier layer is rubber.